Panel system

ABSTRACT

A panel system incorporating a plurality of side by side panels which are joined to one another with tongue and slot connectors. The connectors are configured to permit each panel to be attached to an underlying surface through the connector before a subsequent panel is attached to it.

BACKGROUND OF THE INVENTION

It often is desirable to replace an existing wall quickly and easilywith an updated wall without having to remove the original wall. Onearea where this need exists is with cruise ships and other large vesselswhere the interior surfaces are routinely refurbished. While it ispossible to glue panels on top of the existing wall, it is difficult toremove these panels when subsequent renovations are required. However,it is desirable to remove the previously applied panel since multiplelayered panels would eventually infringe upon the space bounded by thepanels and would create problems with openings in the wall. Moreover, attimes it is desirable to remove the existing wall down to the studs anda wall system used in this environment must also be capable of beingattached directly to the studs.

BRIEF SUMMARY OF THE INVENTION

The subject invention provides a panel system which is constructed frompanels having a tongue member along one edge and a receptacle memberalong the opposed edge. The receptacle member is configured to receivethe tongue member of an adjacent panel with the edges of the panelsabutting one another.

The foregoing and other objectives, features, and advantages of theinvention will be more readily understood upon consideration of thefollowing detailed description of the invention, taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view, looking from the front, of a panelembodying the subject invention.

FIG. 2 is a front elevation view of the panel of FIG. 1.

FIG. 3 is a perspective view, looking from the rear, of the panel ofFIG. 1.

FIG. 4 is a rear elevation view of the panel of FIG. 1.

FIG. 5 is a foreshortened cross-sectional view taken on the line 5-5 ofFIG. 1.

FIGS. 6 and 7 are foreshortened cross-sectional views showing two of thepanels being joined.

FIG. 8 is a cross-sectional view of an edge piece which is an element ofthe invention.

FIG. 9 is a cross-sectional view of another embodiment of the edgepiece.

FIG. 10 is a foreshortened cross-sectional view of a mounting systemwhich is a feature of the subject invention.

FIG. 11 is a perspective view showing how the panels are joined.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Referring now to FIGS. 1 and 2 of the drawings, a panel system comprisesa plurality of panels 10 which interconnect with one another to form awall. The panel system is configured to allow the wall to be used torefurbish an existing wall or to create a wall in new construction. Thepanels have a base sheet 11 with an inner surface 12 which abuts anexisting wall, or a series of wood or metal studs, and an outer surface14 which either serves as a wall surface or is covered with a decorativecover 16 which serves as a wall surface. The decorative cover is atypical wall surface material, such as wood veneer, vinyl, plasticlaminate or tile. The panel is made from a rigid material such as metal,wood, or plastic. One panel material which works well and is readilyavailable is 0.080 inch or 0.090 inch aluminum sheets. The panelsnormally would have parallel opposed edges which would typically bevertical when the panel is installed. The panel can be any size, buttypically would have a standard panel width and height, such as 2′ by8′, 3′ by 8′, or 4′ by 8′, although where appropriate, the panel couldhave a 10′ height. Referring now also to FIG. 5, located on the innersurface 12 of the panel 10 at a first edge 18 is a tongue member 20 andlocated at the inner surface of the panel at a second edge 22 is areceptacle member 24 which receives the tongue member from another paneland allows the two panels to be joined side by side quickly and easilywith the edges of adjacent panels abutting one another.

Referring now to FIGS. 5, 6, and 7, in the embodiment illustrated, thetongue member 20 is a strip of material which extends over substantiallythe entire height of the base sheet. The tongue member has a definedthickness and projects outwardly from the first edge 18 by a firstdistance ‘A’. The tongue member may be of the same material as the basesheet 11, in which case it probably would be the same thickness also.The tongue member is attached to the base sheet by conventional meanssuch as an adhesive, welding, or mechanical. The tongue member needs tooverlay enough of a base sheet to allow a good bond between them. In theembodiment illustrated in the drawings, the receptacle member 24 alsoextends over substantially the entire height of the panel. Thereceptacle member 24 includes a support element 26 which is attached tothe inner surface 12 of the base sheet 11. The support element isseparated from the second edge by a second distance ‘B’ which is atleast as great as the first distance ‘A’, the tongue member extendsoutwardly from the first edge 18. The support element 26 has a thicknesswhich is substantially equal to the thickness of the tongue member.

Attached to the support element 26 is an attachment element 28 whichprojects outwardly from the second edge of the base sheet 11. Theattachment element 28 is attached to the support element in the samemanner that the support element is attached to the base sheet 11. Theside of the attachment element 28 that is not attached to the supportelement is an attachment surface which is configured to be attached toan underlying surface. This underlying surface can be an existing wall30, FIG. 6, or studs 32 in an unfinished wall, FIG. 7. With the existingwall, the attachment element can be attached either by means of anadhesive or a series of opening can be provided to receive screws 34.The attachment element probably would be attached to studs only byscrews.

A wall is fowled with the panels by attaching the attachment element 28of a first panel to the underlying surface. A second panel is attachedto the first panel by inserting the tongue member 20 of the second panelinto the slot 36 formed between the attachment element 28 and the basesheet 11 on the first panel. The attachment element 28 of the secondpanel is then attached to the underlying surface and the process isrepeated to attach additional panels. Attaching the attachment element28 of the second panel to the underlying surface locks the tongue member20 of the second panel in place in the receptacle member 24 of the firstpanel. If there is a corner, a panel can be bent to extend around thecorner, FIG. 11.

Referring now to FIGS. 8 and 9, when it is desired to have an exposededge, an edge piece 38 provides a finished edge. A moulding piece 40 hasa tongue 42 projecting from it. The tongue 42 has a length which isapproximately equal to the length of the tongue member 20 so that it canfit into the slot 36 between the inner surface 12 of the base sheet 11and the attachment element 28. The edge piece 40 can either be flushwith the decorative cover 16 on the outer surface 12 of the base sheet11, FIG. 8, or overlap the decorative cover, FIG. 9. The tongue 42 canbe attached to the molding piece 40 by fasteners such as a series ofscrews 46, FIG. 8, or by an adhesive, FIG. 9. The molding piece can bemade from any suitable material, such as wood or plastic. While the edgepiece shown and described attached to the second edge 22, a similar edgepiece could be provided which attaches to the first edge 18.

Where it is desired to install the panels quickly, or to change themfrequently, a hanger system 48 can be utilized, FIG. 10. The hangersystem includes a hanger element 50 which is attached to the innersurface 12 of the base sheet 11 and extends across the base sheetperpendicular to its edges so that it will be horizontal when the panelis installed. The hanger element 50 includes a body portion 52 which isattached to the outer surface 14 of the base sheet 11, and a hookportion 54 which extends downwardly from the body portion 52 and isseparated from the base sheet. The hanger element interacts with amounted element 56 which is attached to the existing wall 30, or studs36 which the panel covers. The mounted element includes a body 58 whichis attached to the existing wall 30 by a series of screws 60 or anadhesive. Projecting upwardly from the body 58 is a receptacle 62. Thereceptacle is separated from the existing wall 30 by an amount which isequal to the thickness of the hook portion 54. By inserting the hookportion 54 between the body 58 and the existing wall 30, the hangerelement 50, and thus the panel 10, is suspended by the mounting element56. As can be seen in FIGS. 2 and 4, there are several hanger systems atspaced apart vertical locations on each panel.

The terms and expressions which have been employed in the foregoingspecification are used therein as terms of description and not oflimitation, and there is no intention, in the use of such terms andexpressions, of excluding equivalents of the features shown anddescribed or portions thereof, it being recognized that the scope of theinvention is defined and limited only by the claims which follow.

1. A panel system comprising: (a) a plurality of panels each having afirst edge and a second edge which is parallel with and separated fromsaid first edge; (b) said panels including a base sheet having an outersurface and an inner surface; (c) a tongue member which is attached tosaid inner surface of said base sheet along a margin of said first edge,said tongue member having a defined thickness and projecting a firstdistance from said first edge; (d) a receptacle member which is attachedto said inner surface of said base sheet along a margin of said secondedge, said receptacle member having a support element and an attachmentelement; wherein (e) said support element is attached to said innersurface of said base sheet and is separated from said second edge by asecond distance which is at least as large as said first distance andhas a thickness substantially equal to the thickness of said tonguemember; and (f) said attachment element projects from said second edgeof said panel.
 2. The panel system of claim 1 including a decorativecover attached to said outer surface of said base sheet.
 3. The panelsystem of claim 2 wherein said decorative cover is wood veneer.
 4. Thepanel system of claim 2 wherein said decorative cover is vinyl.
 5. Thepanel system of claim 2 wherein said decorative cover is a plasticlaminate.
 6. The panel system of claim 2 wherein said decorative coveris tile.
 7. The panel system of claim 1 wherein said tongue member andsaid receptacle member extend along the entire extent of said first andsecond edges respectively.
 8. The panel system of claim 1 wherein saidattachment element has an attachment surface on the side thereof whichis opposite the side which is attached to said support element, saidattachment surface configured to be adhered to an underlying surface byan adhesive.
 9. The panel system of claim 8 wherein said underlyingsurface is an existing wall surface.
 10. The panel system of claim 1wherein said attachment element comprises one or more openings whichallow said panel to be attached to an underlying wall surface withfasteners.
 11. The panel system of claim 10 wherein said fasteners arescrews.
 12. The panel system of claim 1 wherein said panel is bentintermediate said first and second edges to provide a corner.
 13. Thepanel system of claim 1 including an edge piece which is attachable tosaid panel adjacent said second edge of said base sheet after saidattachment element has been shortened to be coterminous with said secondedge, said edge piece comprising: (a) a molding piece; and (b) a tonguewhich projects from said molding piece by an amount approximately equalto said first distance.
 14. The panel system of claim 13 wherein saidmolding piece is flush with said outer surface of said panel.
 15. Thepanel system of claim 13 wherein said molding piece partially overliessaid outer surface of said panel.
 16. The panel system of claim 1including a hanger system, comprising: (a) a hanger element which isattached to said inner surface of said base sheet and extends acrosssaid base sheet perpendicular to said first and second edges; (b) saidhanger element having a body portion which contacts said base sheet, anda hook portion which projects downwardly from said body portion; (c) amounted element which is attached to a wall; (d) said mounted elementhaving a body portion which contacts to said wall; and (e) said mountedelement having a body which contacts said wall, and a receptacle whichis configured to releasably engage said hook portion of said hangerelement.
 17. The panel system of claim 16 wherein there are multiplehanger elements and multiple mounted elements.
 18. A method forconstructing a wall with the panels of claim 1, comprising: (a) placinga first one of said panels vertically against an underlying surface; (b)attaching the support element of said first one of said panels to saidunderlying surface; (c) inserting the tongue of a second one of saidpanels into the slot formed between the base sheet and receptacle memberof said first one of said panels; (d) urging said second one of saidpanels towards said first one of said panels until the first edge ofsaid second one of said panels abuts the second edge of said first oneof said panels; (e) attaching a support element of said second one ofsaid panels to said underlying surface; and (f) repeating steps (c)through (e) until the wall is constructed.